Improvement in the manufacture of iron and steel



whom .concern .'.Beitflrnown thj't waFnnuD l and YrnGrr-xW. Buslinien,of Bridporaixr view; Fic.

.iremity PATENT ".Orricn.

P. 'AND BLANCHAnnoF BRIDPORT, vEnMoNr.

insgeheim' iii-int'nmiumunt or IRON 'AND STEEL.

P. FLETCHER the-'county of Addison `and State of Vermont, havelinventeda new anduseful Improvement .'in .the Manufacture of Steel and Malleableiron; and` we do hereby Adeclare that the fol'- lowing is al full,clear, and 4exaet description thereof, reference'being had to theaccompa-- Dying drawings, and'totheletters of reference marked thereon,which form a part of this specification, in which- Figure l is a sideelevation; Fig. 2, aplan 3, a. vertical longitudinal section throughlinen b, Fig; 2;'Fig. 4, a cross-section through line c d, Eig. 3;liig.` 5, aplan view-nf axle. Src. ;A Figj, acrosssection throughliney',v fg. Fig. 1; and Fig. -7 ,"abroken plan ofthe bot-V tom ofvessel.

@grenoble others slilledfin theart to sind use our invention, weVv'iillnovr describe itsconstructionfand operation.

A rep rcsents the converting-vessel, mounted upon its axle B. The axleBis irmly snpported' liy theframeC. Bymeans of its axle B a tilting,rocking, or revolving motion may be given tothe converting-vessel A.Snrronnding the axle B of the converting-vessel A, and connected tothatlvessel, is seen the circular apartment F. Fitted bya suitablebearing-surface to the circular apartment E is seen the stationary diskD. Connected with the disk'D and opening into the apartment F is theblastfpipe E. Connected by one exwith the apartment F is seen the air orblast pipes G'G. 'The open 'extremity of the air or blastpipe E may heconnected by any suitable conductor with a receiver orreservoircontaining thejeompressed gaseous element or elements-requiredin the, process of reducing andpurifying the molten metal. It

will be observed that whatever maybe the po'- sition ofthe'converting-vessel A the passage isalways freebetween the air erblast pipe E and the airor blast pipes G G. Let K K represent twosymmetrical apartments or pockets of the converting-vessel A. Theseapartments or pockets serve several important uses in the invention;first, as vessels to` hold the molten metal during the process ofconvertion or puriieation; second, as vessels in which the pro cess ofatomizing or globularizing is carried cess of converting thecarbnret ofiron into steel and malleable iron may be completed with a'pnddling-tool, if desired; fourth', they serve .as vessels or cruciblcsfor melting wrought-iron or east-iromor. any variety of 'iron ore or anysubstance that will aid in the.

tuse angle, is seen the depression M.

Extending upward at a greateror less angle,

and terminating or opening in each wall of, the depression M, oppositeor facing the pock-` ets -K K, are the blast-pipes NN. These pipes reconnected, through the apartment F, with the blastpipe E,.and areprovided with the valves O O, to bar or regulate the passage of thegaseous element or elements through them.

l Connected with apartment F are the pipes. G G.- These pipes arefurnished with the valves' S S, to regulate the passage of the gaseousele- "ments through them.. Working in 'the depression Mis seen thevalvea. -lilirectly over the axle B of the converting-vessel A. is theextremity of the rod b towhieh the valve a is attached. j

d represents a lever attached to rod b, by

means ot' which the valve a can be worked outside of vessel A. Theoffice or. nseof the valve a is to close the extremity of the blastpipesN N, opening into the depression M. It `:vill be observed that whiletheextremity of one of the blast-pipesN is closed by thevalve a, theextremity of the other will be open. By

this means the molten metal may be prevented 'from entering the openextremity oi' Veither ot the blastpipes N N, while the jet of gaseouselements is issuing from the pipe on' the opposite side ol' thedepression M during the process of reduction or purification of themolten metal. We would, however, remark that we on third, aspuddling-vesselsinivhich the proi vr reflectedwhile the process ofatomizing or glohularizing is going on.

.T T designate two openings, situated'one at or near each extremityofthe vessel A. These openings serve in several important uses First,

' through them the metal, molten or otherwise,

is introduced into the converti ng-vesse1; second, through them theproducts ofv combustion lescape during the process of conversion orpurification; third, lbythem the process of skimniing the molten metalorthe removal of scoria or slag takes place; fourth, through them theprocess of peddling is 'carried on; fifth, by means of them therecarbonization of' the molten metal may take place by the introductionof certain suitable substances into the converting-vessel; and also bythem the molten metal is poured from the vessel when the process ofconversion or purification is complete.

J J represent two reverberatory furnaces, connected each with theconverting-vessel A, about midway its extremities.

U designates the passage by which the reverberatory furnace is connectedwith, the apartment or pocketK of 1the vessel A. This I vpassage isinclined downward, so as iso-deflect the dame or products of combustionissuing from said furnace against the bottom or'iioor of' apartment K.Fuel is introduced into the reverberatory furnaces J J by means of theirlids I I. The reverberatory furnaces are furnished with blasts by meansof the pipes P P. 1t may be here remarked that the connection,arrangement, construction, and operation" of each reverberatory furnace,as respects the converting-vessel A, areidentical. These furnacesperform several important officessuch as affording means of melting castorwrought iron or any variety ofiron ore within the apartments K K; forkeeping the metal in a suiciently fluid or molten state while theprocess of atQmizing or globularizing or while the process of puddlingis going on; for carbonizing or decarbonizing or otherwise purifying themolten metal contained in the pockets K K, according as the flames orproducts of coinbustion issuing from them arecharged with carhouzingordecarbonizing or other purify.- ing or eliminatve gases'or vapors. A Qrepresents a lever, by means of which the vessel A may bedepressed,-elevated, tilted, rocked, or revolved to agreater or lessdegree required inthe introduction, conversion, and pouring of themetal.We would have remarked that we do not confine ourselves to the mechanismdescribed, but to any means sib stantially the same by which the sameeffect is produced. In the practical operation of our invention, fuel isfirst introduced into the reverberating furnacesT T, and kindled. Thevalves O O in the blast-pipes P P, connecting these furnaces through theapartlneutF with the blast-pipe E,are opened. The Haine or products ofcombustion are thrown by this means, l through the openings U Ut intothe'apart-m'ents 'o 'r pockets K K of the converting -vessel A, pointingto the floor or bottom of the i same. Wlfen the pockets K K are heatedto a suificient degree of intensity, the con verting-vessel may,

by means of the lever Q, be rocked or revolved or tilted toa suit-abledegree to conveniently yin-A troduce'at one of the openings Smoltencastiron direct froma blast,or any other form of furnace, orwrought or cast iron in the form of scrap or pig.

purification will commence at once,\vhileifthe wrought 01 cast iron issingly introduced, or introduced mixed with molten metal, theprocesswill be more or less delayed` according to the time required tomelt the samein the heat afforded bythe reverberating furnaces; We wouldhere remark that the-different varieties ofA iron ore are not introducedinto the converting-vessel to be melted, "except in combinat-ion withthe melted metal, before the process of conversion or purificationcommences,

but may be added after such process has begun, in such quantities as maybe deemed desirable. Such addition we do not, however, considerindispensable in the process.

By theaddition of wrought or cast iron or iron ore, n'suitablequantities, totheumo'lte'n metal after theprocess of conversion orfpurification 'has begun, any surplus heat beyond.

what is"- required to keep them'etaljn a liquid or molten state may7 beutilized, and b v such( means a proper quantity'of i-ron ore or wrought*or cast i'ron scraps may be economicallycon When" the verted into thedesired product. metal introduced into thefpocket K of the ves'- sel isin a sufficiently liquid state from previ, ous heat, or from the effectsof such heat combined with that of' the flame or producs 0f combustionfrom the reverberating furnace, the extremity of the vessel A,containing the molten metal,'is raised, tilted, or revolved by means ofthe lever Q, Iso that the molten metal in a stream flows over` thecentral portion of the floorof the Vessel A into the -depressionpression M is actuated so as to close` the extremit-y of'one ofthe pipesN N, opening into "the depression M, oppositeto its fellows, from whichthe jet of gaseous elements issues into the converting-vessel. Then, asthe melted metal falls into the depression M, the jet or blast ofgaseous elements issuing from the open extremity of the blast-pipeN,'with a In case the molten cast-iron is." alone introduced, theprocess of conversion or greater or lesser force and'velocitytrikes thel varieties of metal, expedient to have the blasts stream of meltedmetal and forcibly carries or of the reverberating furnaces consist of adifprojects it in a globular or atomic condition over the depression Minto the opposite apartment or pocket K ofthe vessel A.

lt may here be observed that the blast-pipes N N are placed at such anangle that thejcts ot' gaseous elements issuing from them and strikingthe molten metal causes the globules, atoms, or particles into whichsuch stream becomes dispersed or divided, to forcibly strike against-theinclined planes R R,formed by.`

thel root' of theconverting-vessel. Then` as the jet of gaseous elementsmay consist of air, su perheated steam, 'free oxygen, hydrogen.

-ammoniacal or chlorine gas, or any mixture ol' the saine, or anyhydrocarbon vapor, or any volatile-or gaseous element or elements thatmay be required ro effect the conversion and purification of the moltenmetal, it is clearly seen-that every atom, globule, or particle of thelmelted metal may be brought into fr e'c and immediate contact with thegaseous elements required to e'eot its conversion and purification. Theatom, globule, or particle of molten metal forciblystriking the inclinedplane R, formed by the roof of the vessel A,

becomes flattened or reflected, thereby presen ting'a new surface to theaction of the gaseous elements by which it may be surrounded. The atom,globule, or particle of' molten metal, after Strikingor being reectedfrom the ineline plane, passes or vfalls directly into the flame fromthe furnace T, that points to the flor'otthe vessel A. By this meansevery atom7 particle, or globule ofthe melted metal thatpasses from oneapartment to the other on the opposite side is exposed to the directaction of the flame issuing from the reverberating4 furnaces. It will beobserved that the heat-of these furnaces is used and applied,

' most economically.

V(airbcmfcontaine'din the molten metal, operates .favorably in effeeting its combustion und elimination, We would here remark that the blastsfor supplying; the reverberating fu rnaees are shown as ldesired incommon with those used for atomizing or globularizmg purposes, from theapartment f'F, connected with the blast- Ppe E We would -be understoodthat we (lo-not 'confine ourselves to this arrangement. It' necessary,separate blasts may be provided for the said furnaces. It 4may be found,in certain ferent gaseous element or elements from those used in theatomizing or glolmlarizing process. We would be understood to claim thisvariation.

By elevating, tilting, rocking', or revolving the vessel Ato a certaindegree the molten metal will all pass over in a globular or atomiccondition into the opposite apartment or pocket. Then, by continuing thesame process to a still greater degree, the slag or seoria or otherimpurities on the top of the melted metal may be poured off through theopening S, near the extremity of the vessel A, or removed with asuitable instrument. vWe would here remark that during the process ofremoving the slag or scoria from the molten metal, or any othernecessary operation pertaining -to its conversion or purification, thevalve O in the pipe P of the furnace T may be closed, which will allowany such'necessary operation to be performed without-diiiculty. At thispoint in the process a portion of the 4molten metal may be removed fromthe vesthe position of the valve a, soithat the ex-v tremity oftheblast-pi pe that has been closed during` the operation just describedmay be opened and its fellow on the opposite side of the depression beclosed. This pipe will afford a jet or blast ot' gaseous elements on theopposite side ofthe depression M to th at whose or atomic condition, agreater or less n umber` of times from one apartment to its fellow onthe opposite side, and the process of skimming or testing performed asoften as desired.

We would here observe that we do not limit ourselves to the precisemethod shown for repeatedly/.converting or purifying the melted t metal,.but that we claim any manner or method whereby a stream of molten metalis repeat edly reduced or dispersed to 'a globular or atomic state bythe saine jet or jets of a gaseous ments is suicient to convert orpurify a large body of melted metal, and the process may also by thismeans be indefinitely prolonged for the removal of the, slag or scoriaand other impurities. During the process of conversion or purificationthe addition of suitable quantitiesof wrought-iron or iron ore willshorten the process of converting the carburet of iron into steel ormalleable iron. Bypassing the molten metal, in a globular or atomicstate, a greater orl'ess number of -ti mes from one`apartment of thevesselA to its fellow on the opposite side it may be reduced to anydesired grade of steel or malleable iron.

` It will beobserved that by the elevating, rocking, or revolving,tilting; and depressing motionof the converting-vessel, and by means ofthe valves in the air'or blast pipes that furnish the atomizing orglobularizing jets, the size or volume of the stream of molten metal andthe size or volume of the jet or jets of gaseous element or yelementsare' completely under the control of the-operator. Thus, by increasingordiminishing thesize of the stream of molten metal with a given size tothe jetor jets of gaseous elements,'or by `iu'reasing or diminishingthesizeof the jets of gaseous elements with a given size to the streamof molten metal, a greater orless 'amount of the carbon, sulphur, orphosphorus, or any impuri ties contained in the-moltenmetal, for whichthe gaseous elements contained-in the jets may have a chemical orelective .,anity, maybe removed or eliminated from the molten mtal atpleasure; also, by charging'the blasts of the reverberatingjfurnaces T Tto agreater or less degree with a; surplus gaseous element orelementsthat have an elective or chemical affinity w'ith the deleterioussubstance orqualitiescontained in the molten metal, such substances orqualities may be to a greater or less Vextent removed or eliminated fromthe molten `metal at pleasure.

It willhere be particularly observed that by the process heretofore setfort-h diiierent grades of steel may be produced from the carburet ofiron b y several different modes or methods,

which the quality of the iron to be converted and the-qualityof steel tobe produced must determine. j The skill and judgment of the operatormust determine the proper method. The molten metal may be passedfronrone apartment or pocket K of the vessel A, in a globular or atomiccondition to its fellow on the opposite side of thevessel, and thisproblasts of the lrevexjberating furnacesmaybe tenmetal maybe reduced bythe atomizing or globularizing process to nearly the desired degrec,after which the process may be completed with a puddling-tool introducedinto the opening S nea'r each of theextremitiesof thevessel -A By thismode puddled steel or iron may beproduced at the close of the operationin precisely-the' same manner as in ordinary puddlng-t'urnaces, with butlittle labor. We do not'in this connection confine ourselves to theprecise method shown; but we claim anymethod -by means of whichl themolten metal is partallyconverted or purified by the atomizi'ngor-globularizing process, the process being completed with apuddlin'g-tool or its equivalent.

We would here observe that we do notlimit ourselves to the means andprocesses described in this speciiication to the production 'andmanufacture of steel or malleable iron, but that we-do claim by suchmeans andproccsses the manufacture or production of any grade or qualityof metal intervening between the carburet of iron or cast-iron andsteel. We would here also remark that we do, not con- [ine ourselves inthis invent-ion tothe conver sion or purification of iron alone, butthat we' claim the process of atomizing and globularizing, and allof thefeatures embodied in this'4 invention, applied to any other-uietalbsides iron by means of. which'such metal maybe purifiedorrefined. The purification' of sil#` ver containinglcad'as an impurity oralloy -may be eected' by this processwith great fa cility.`

Having thus described our invention, what `we claim as new, and desire.to secure by Letters Patent, is,-

1. The use and. employment of a tilting, rocking, o'r revolvingconverting vessel or bath for the purpose of exposing .the melted metalcontained thereinin aglobular or atomicstate a greater or less number oftimes to a jet or jetsvof gaseous element or elements, substan'- tiallyas and for the purposes set forth.-

2. The repeated forcibleieduction or dis-` persion of the molten metalinto a globularor atomizing condition by the samejet or jetsof a gaseouselement oiielements, substantially as `v and for the purposesspecified.`

, 3. The introduction into Atheiblast ot a verberating furnace,whensuchtfurnacisiom bi ned with a converting vessel or bath in Whiehlthe molten metal is lred'uoedto a globular or atomic state, any gaseousor volatile element or elements that will by chemical affinity eliminateor remove any deleterious lelement contained 4in the molten metal, orassist in the production ofthe desired product.

4. The use and employment of la tilting, rocking, or revolvingconverting vessel or bath containing two apartments or pockets forholding the molten metal during the process of convessel or bath inwhich the molten metal may bereduced to a globular or atomic condition,V4substantially as and for the purpose set forth.

, The introduction of wrought or cast iron,

' or"-'`ny"vaiiety of iron ore, into a converting vessel oliA bath inwhich the molten metal is reduced'to a-globular or atomic conditionwithin the eiect or in the presence of a .dame or prodnctsfofvcombustion from a reverberating furnace, substantially as and for thepurposes described.

8. The arrangement of blast-pipes,with their 4necessary valves,connected with the apartment of the converting-vessel, in combinationwith such Vessel and the reverberating furnaces, for the purpose ofsupplying and regulating the jet of gaseous elements required to reducethe `,metal to a globular or atomic state, and to supply and regulatethe necessary blast for the reverberating furnaces, substantially i nthe maunerspecified.

9. ,The introduction of spiegeleisen, spathic ore, or anyl suitablesubstance containing a greater` or less per cent. of carbon, into aconver-'ting vvessel or bath combined with a reverberatiug furnace, andin`which the molten metal is reduced to a globular or atomic conditionby ajet or jets of gaseous elements, substantially as and for thepurpose set forth.

10. The introduction ot any hydrocarbon vapor, or any gaseous orvolatile element containing a greater or less per cent. of carbon, intothe jet or jets by which the molten metal is atoinized or globularizedwithin the converting vessel or bath, substantiallyas and for thepurposes described.

11. The openings at each extremity of the converting-vessel, for thepurpose of .the exil; of the products of combustion, and for theintroduction of any suitable instrument for the removal of the scoria`or slag from the molten metal, or for working the met-al with apuddling-tool,substantiallyin the mannerset forth.

12. The lever Q: or its equivalent', for tilt ing, rocking, o'rrevolving the converting-vessel, substantiallyas and inthe manner specilied.

13. The forcible dispersion oiastream of inolten metal into a globularor atomic state, in the production oi' any desired grade or variety ol'product between the carburet of iron, or what is commonlyr known as castiron and steel, substantially as and in the manner described.

14. Rising and falling pockets or apartments forholding the molten metalduring the process of conversion or purification, substantially as andfor the purpose se'tforth.

15. The use ofthe valve u in the depression M of the com'erting-vesselA. substantially as and for the purpose specified.

lli. The use ot the stationary disk D,'in eombination with the apartnient F, and blast-pipe E,wl1en used in connection withaconvertingvessel in which the molten metal is reduced to a globular oratomic stale, substantially as and iu the manner set forth.

17. In a tilting, rocking, or revolving con 'vertingvessel to which areattached rever-

